Condensate pan for a heat exchanger

Abstract

A furnace for a heating, ventilation, and air conditioning (HVAC) system includes a condensate pan including a base wall and a plurality of side walls extending from the base wall. The base wall and the side walls define an internal volume configured to receive liquid condensate from a tube of the furnace. The condensate pan also includes a first mounting aperture, a second mounting aperture, and a plurality of drain ports formed therein, each drain port extends through the base wall and is formed at an intersection of two side walls of the side walls. The condensate pan is configured to mount to a panel of the furnace via a first fastener extending through the first mounting aperture. The furnace also including an inducer blower configured to mount directly to the condensate pan via a second fastener extending through the second mounting aperture.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from and the benefit of U.S. Provisional Patent Application No. 63 / 558,456, entitled “CONDENSATE PAN FOR A HEAT EXCHANGER,” filed Feb. 27, 2024, which is hereby incorporated by reference in its entirety for all purposes.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure and are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be noted that these statements are to be read in this light, and not as admissions of prior art.

[0003] Heating, ventilation, and / or air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. For example, an HVAC system may include one or more heat exchangers, such as a heat exchanger configured to place an air flow in a heat exchange relationship with a working fluid of a vapor compression circuit, a heat exchanger configured to place the air flow in a heat exchange relationship with combustion products (e.g., a furnace), or both. In general, the heat exchange relationship(s) may cause a change in pressures and / or temperatures of the air, the working fluid, the combustion products, and so forth. As the temperatures and / or pressures of the above-described fluids change, liquid condensate may form in or on the associated heat exchangers.

[0004] Existing systems may include a condensate pan for collecting condensate formed in or on the heat exchangers. Unfortunately, traditional condensate collection and drainage systems are susceptible to various drawbacks. For example, traditional condensate pans may limit an orientation in which a heat exchanger may be positioned. Furthermore, traditional condensate pans may be inadequate for collecting and draining the condensate, which may lead to degradation of components of the HVAC system and / or related operating interruptions and inefficiencies in the HVAC system. Traditional condensate pans and / or condensate collection and drainage systems may be complicated and expensive to manufacture. Accordingly, it is now recognized that improved condensate management systems for HVAC systems are desired.SUMMARY

[0005] A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0006] In an embodiment, a furnace for a heating, ventilation, and air conditioning (HVAC) system includes a condensate pan including a base wall and a plurality of side walls extending from the base wall. The base wall and the side walls define an internal volume configured to receive liquid condensate from a tube of the furnace. The condensate pan also includes a first mounting aperture, a second mounting aperture, and a plurality of drain ports formed therein, each drain port extends through the base wall and is formed at an intersection of two side walls of the side walls. The condensate pan is configured to mount to a panel of the furnace via a first fastener extending through the first mounting aperture. The furnace also includes an inducer blower configured to mount directly to the condensate pan via a second fastener extending through the second mounting aperture.

[0007] In another embodiment, a condensate pan for a furnace of a heating, ventilation, and / or air-conditioning, (HVAC) system includes a base wall, a plurality of side walls extending from the base wall and crosswise to the base wall, and an internal volume defined by the base wall and the plurality of side walls. The internal volume is configured to receive a heat transfer fluid and a liquid condensate from a heat exchanger of the furnace. The condensate pan also includes a first drain port extending through the base wall and formed at a first corner of the internal volume defined by a first side wall of the plurality of side walls and a second side wall of the plurality of side walls, where the first drain port is configured to drain the liquid condensate from the internal volume to an exterior of the condensate pan in a first orientation of the condensate pan. The condensate pan also includes a second drain port extending through the base wall and formed at a second corner of the internal volume defined by a third side wall of the plurality of side walls and a fourth side wall of the plurality of side walls, where the second drain port is configured to drain the liquid condensate from the internal volume to the exterior of the condensate pan in a second orientation of the condensate pan.

[0008] In a further embodiment, a furnace for a heating, ventilation, and air conditioning (HVAC) system includes a vestibule panel including a first side and a second side, opposite the first side, a burner assembly coupled to the vestibule panel and disposed on the first side of the vestibule panel, where the burner assembly is configured to generate combustion products. The furnace also includes a first plurality of tubes coupled to vestibule panel and disposed on the second side of the vestibule panel, where the first plurality of tubes is configured to receive the combustion products from the burner assembly and a second plurality of tubes coupled to the vestibule panel and disposed on the second side of the vestibule panel, where the second plurality of tubes is configured to receive the combustion products from the first plurality of tubes. The furnace further includes a condensate pan coupled to the vestibule panel and disposed on the first side of the vestibule panel, where the condensate pan defines an internal volume configured to receive the combustion products and a liquid condensate from the second plurality of tubes. The condensate pan includes a first condensate drain port formed in a first corner of the internal volume and a second condensate drain port formed in a second corner of the internal volume, diagonally opposite the first corner, and the first condensate drain port and the second condensate drain port are each configured to direct the liquid condensate out of the internal volume in different orientations of the condensate pan. The furnace also includes an inducer blower mounted directly to the condensate pan and configured to draw the combustion products out of the internal volume.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

[0010] FIG. 1 is a perspective view of a building having an embodiment of heating, ventilation, and / or air conditioning (HVAC) system for environmental management that may employ one or more HVAC units, in accordance with an aspect of the present disclosure;

[0011] FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit that may be used in the HVAC system of FIG. 1, in accordance with an aspect of the present disclosure;

[0012] FIG. 3 is a cutaway perspective view of an embodiment of a residential, split HVAC system, in accordance with an aspect of the present disclosure;

[0013] FIG. 4 is a schematic illustration of an embodiment of a vapor compression system that can be used in any of the systems of FIGS. 1-3, in accordance with an aspect of the present disclosure;

[0014] FIG. 5 is a perspective view of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure;

[0015] FIG. 6 is a perspective view of an embodiment of a condensate pan that may be utilized with a furnace system, in accordance with an aspect of the present disclosure;

[0016] FIG. 7 is a perspective view of an embodiment of a condensate pan that may be utilized with a furnace system, in accordance with an aspect of the present disclosure;

[0017] FIG. 8 is an expanded perspective view of an embodiment of a condensate pan that may be utilized with a furnace system, in accordance with an aspect of the present disclosure;

[0018] FIG. 9 is a perspective view of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure;

[0019] FIG. 10 is a side view of a portion of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure;

[0020] FIG. 11 is a perspective view of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure;

[0021] FIG. 12 is a perspective view of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure; and

[0022] FIG. 13 is a side view of a portion of an embodiment of a furnace system, including a condensate pan, that may be incorporated in an HVAC system, in accordance with an aspect of the present disclosure.DETAILED DESCRIPTION

[0023] One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be noted that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be noted that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0024] When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be noted that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0025] As used herein, the terms “approximately,”“generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within + / −5%, within + / −4%, within + / −3%, within + / −2%, within + / −1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within + / −5%, within + / −4%, within + / −3%, within + / −2%, within + / −1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,”“slope,”“perpendicular,”“parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

[0026] The present disclosure is generally directed to heating, ventilation, and / or air conditioning (HVAC) systems. The HVAC system may include a vapor compression circuit that circulates a working fluid for conditioning a supply air flow, a furnace system that circulates combustion products (e.g., heat transfer fluid) for conditioning a supply air flow, or both. For example, the vapor compression circuit may include at least one heat exchanger configured to receive the working fluid. Further, at least one fan may be employed and configured to direct the supply air flow over the at least one heat exchanger. The supply air flow may then be directed into a space to condition the space.

[0027] In some embodiments, the HVAC system may include a furnace system (e.g., a condensing furnace) configured to generate a heated supply air flow that is provided to the conditioned space. For example, the furnace system may include a heat exchanger having tubing that is configured to receive relatively hot combustion products (e.g., ignited flue gas). The furnace system may also include a blower configured to direct the supply air flow across the tubing, thereby placing the supply air flow in a heat exchange relationship with the relatively hot combustion products to heat the supply air flow. Thereafter, the heated supply air flow may be directed into the conditioned space.

[0028] In some circumstances, condensate may form in or on one or more heat exchangers during operation of the HVAC system, such as an evaporator or condenser of the vapor compression circuit and / or the heat exchanger of the furnace system. For example, combustion products within the heat exchanger of the furnace system may cool as heat is transferred to the supply air flow, which may cause moisture within the combustion products to condense. As another example, during a cooling mode of the HVAC system, the cooled supply air flow may be directed across the heat exchanger of the furnace system, which may not be operating. Even so, air (e.g., ambient) may be present within the tubing of the heat exchanger of the furnace system. In some instances, the cooled supply air flow may cause the air within the furnace system heat exchanger to cool, thereby causing moisture contained within the air to condense. Existing condensate management systems may be configured to remove and discharge at least some of the condensate from the heat exchanger. Unfortunately, traditional systems may have various limitations. For example, existing furnace systems may include a condensate pan that limits a number of suitable orientations in which the furnace system heat exchanger may be positioned. In some existing systems, a furnace system heat exchanger may be restricted to one orientation (e.g. “upwards”). Further, traditional condensate pans may be complicated and / or expensive. For example, existing furnace systems having traditional condensate pans may utilize numerous additional structural components to attach other structures (e.g. an inducer blower) to the furnace system. Furthermore, traditional condensate pans may restrict flow of combustion products through the heat exchanger of the furnace system. For example, existing condensate pans may have an internal volume that creates pressure differentials and causes decreased air flow through the furnace system

[0029] It is now recognized that improved condensate pans and related features may enable orientation of the furnace system in multiple configurations. For example, condensate pans in accordance with the present techniques may have a first drain port located or formed in a first corner of the condensate pan and a second drain port located or formed in a second corner of the condensate pan that is opposite (e.g., diagonally opposite) the first corner. The disclosed configuration enables positioning of a furnace system having the condensate pan in at least four separate furnace orientations, while also enabling drainage of liquid condensate in each of the separate orientations. Further, the condensate pans disclosed herein may be manufactured as a single, integrally formed piece. The simplified design may be more economical to manufacture and may also function as a rigid support structure for other components of the furnace system to be mounted thereto. In this way, present embodiments may enable a reduction in other components typically included in furnace systems. Furthermore, the configurations of the condensate pan described herein enables placement of the condensate pan between a vestibule of the furnace system and an inducer blower, external to the vestibule, to create an improved gap between the inducer blower and the vestibule that enables enhanced flow of combustion products through the furnace system.

[0030] Turning now to the drawings, FIG. 1 illustrates an embodiment of a heating, ventilation, and / or air conditioning (HVAC) system for environmental management that may employ one or more HVAC units. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, a sensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

[0031] In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12 with a reheat system in accordance with present embodiments. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower, integrated air handler, and / or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in FIG. 3, which includes an outdoor HVAC unit 58 and an indoor HVAC unit 56.

[0032] The HVAC unit 12 is an air-cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and / or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one refrigeration circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more working fluid circuits (e.g., refrigeration circuits) for cooling an air stream and a furnace for heating the air stream.

[0033] A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and / or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and / or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.

[0034] FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. In the illustrated embodiment, the HVAC unit 12 is a single package unit that may include one or more independent refrigeration circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12 may provide a variety of heating and / or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. As described above, the HVAC unit 12 may directly cool and / or heat an air stream provided to the building 10 to condition a space in the building 10.

[0035] As shown in the illustrated embodiment of FIG. 2, a cabinet 24 encloses the HVAC unit 12 and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12. In certain embodiments, the rails 26 may provide access for a forklift and / or overhead rigging to facilitate installation and / or removal of the HVAC unit 12. In some embodiments, the rails 26 may fit into “curbs” on the roof to enable the HVAC unit 12 to provide air to the ductwork 14 from the bottom of the HVAC unit 12 while blocking elements such as rain from leaking into the building 10.

[0036] The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more refrigeration circuits (e.g., working fluid circuits). Tubes within the heat exchangers 28 and 30 may circulate refrigerant, such as R-410A, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the refrigerant undergoes phase changes and / or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and / or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the refrigerant to ambient air, and the heat exchanger 30 may function as an evaporator where the refrigerant absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of FIG. 2 shows the HVAC unit 12 having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12 may include one heat exchanger or more than two heat exchangers.

[0037] The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and / or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.

[0038] The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the refrigerant before the refrigerant enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and / or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other things.

[0039] The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.

[0040] FIG. 3 illustrates a residential heating and cooling system 50, also in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include refrigerant conduits 54 (e.g., working fluid conduits) that operatively couple the indoor unit 56 to the outdoor unit 58. The indoor unit 56 may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 58 is typically situated adjacent to a side of residence 52 and is covered by a shroud to protect the system components and to prevent leaves and other debris or contaminants from entering the unit. The refrigerant conduits 54 transfer refrigerant between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid refrigerant in one direction and primarily vaporized refrigerant in an opposite direction.

[0041] When the system shown in FIG. 3 is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a condenser for re-condensing vaporized refrigerant flowing from the indoor unit 56 to the outdoor unit 58 via one of the refrigerant conduits 54. In these applications, a heat exchanger 62 of the indoor unit functions as an evaporator. Specifically, the heat exchanger 62 receives liquid refrigerant, which may be expanded by an expansion device, and evaporates the refrigerant before returning it to the outdoor unit 58.

[0042] The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or the set point plus a small amount, the residential heating and cooling system 50 may become operative to refrigerate additional air for circulation through the residence 52. When the temperature reaches the set point, or the set point minus a small amount, the residential heating and cooling system 50 may stop the refrigeration cycle temporarily. The outdoor unit 58 may include a reheat system in accordance with present embodiments.

[0043] The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate refrigerant and thereby cool air entering the outdoor unit 58 as the air passes over the outdoor heat exchanger 60. The indoor heat exchanger 62 will receive a stream of air blown over it and will heat the air by condensing the refrigerant.

[0044] In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace system 70 where it is mixed with air and combusted to form combustion products (e.g., heat transfer fluid). The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.

[0045] FIG. 4 is an embodiment of a vapor compression system 72 that can be used in any of the systems described above. The vapor compression system 72 may circulate a working fluid (e.g., refrigerant) through a circuit starting with a compressor 74. The circuit may also include a condenser 76, an expansion valve(s) or device(s) 78, and an evaporator 80. The vapor compression system 72 may further include a control panel 82 that has an analog to digital (A / D) converter 84, a microprocessor 86, a non-volatile memory 88, and / or an interface board 90. The control panel 82 and its components may function to regulate operation of the vapor compression system 72 based on feedback from an operator, from sensors of the vapor compression system 72 that detect operating conditions, and so forth.

[0046] In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and / or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. The motor 94 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.

[0047] The compressor 74 compresses a refrigerant vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The refrigerant vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The refrigerant vapor may condense to a refrigerant liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid refrigerant from the condenser 76 may flow through the expansion device 78 to the evaporator 80.

[0048] The liquid refrigerant delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid refrigerant in the evaporator 80 may undergo a phase change from the liquid refrigerant to a refrigerant vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the refrigerant. Thereafter, the vapor refrigerant exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.

[0049] In some embodiments, the vapor compression system 72 may further include a reheat coil. In the illustrated embodiment, the reheat coil is represented as part of the evaporator 80. The reheat coil is positioned downstream of the evaporator heat exchanger relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.

[0050] It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.

[0051] Further, any of the systems illustrated in FIGS. 1-4 may include or operate in conjunction with a furnace in accordance with the present disclosure, such as the furnace system 70 of FIG. 3. For example, the furnace system 70 of FIG. 3 may generate combustion products and then rout the combustion products through tubes of the furnace system 70. In some embodiments, the furnace system 70 may be a condensing furnace having a first set of tubes, which may be referred to as primary tubes, and a second set of tubes, which may be referred to as secondary tubes. An air flow may be directed over the tubes of the furnace system 70, for example by a fan or blower, such that the air flow is heated by the combustion products flowing within the tubes of the furnace system. Thereafter, the heated air flow may be delivered to a conditioned space. Unfortunately, in some instances, condensate may form within the tubes of heat exchanger of the furnace system 70.

[0052] In accordance with the present disclosure, a condensate pan may be utilized to collect and drain liquid condensate that forms within the furnace system. The condensate pan may be positioned between an inducer blower and vestibule of the furnace. The inducer blower may be coupled (e.g. fastened) directly or indirectly to the condensate pan. The configuration of the condensate pan between the inducer blower and furnace vestibule may define an improved gap that enables more uniform pressure distribution and improved flow rate of combustion products through the combustion furnace system. Further, the condensate pan may be a single, integrally formed structure. In some embodiments, the condensate pan may include a base wall and four side walls that define an internal volume configured to receive liquid condensate from heat exchanger tubes of the furnace system. The base wall may have drain openings or drain ports located in one or more corners of the base wall of the condensate pan. The drain ports enable drainage of liquid condensate from the internal volume, thereby reducing likelihood of degradation caused by the presence of liquid condensate within the furnace system and associated operating interruptions and inefficiencies. Further, the drain ports may be configured to enable drainage of the liquid condensate in multiple furnace configurations. For example, a first drain port may be located or formed in a first corner of the condensate pan defined by the base wall, a first side wall, and a second side wall. A second drain port may be located or formed in a second or opposite (e.g., diagonally opposite) corner, defined by the base wall, a third side wall, and a fourth side wall. In this way, the condensate pan may drain liquid condensate building up in the internal volume in at least four configurations of the furnace.

[0053] With the foregoing in mind, FIG. 5 is a perspective view of an embodiment of a furnace system 100 (e.g., a furnace), including a condensate pan 102, in accordance with aspects of the present disclosure. For example, the furnace system 100 may correspond to the furnace system 70 in FIG. 3. In the embodiment illustrated in FIG. 5, the furnace system 100 includes a primary heat exchanger section 104 coupled to a first vestibule panel 106 of the furnace system 100 (e.g., a set of primary tubes 108 of the primary heat exchanger section 104 may be coupled to the first vestibule panel 106 proximate inlets to the primary tubes 108). The furnace system 100 may also include a secondary heat exchanger section 110 coupled to a second vestibule panel 112 of the furnace system 100 (e.g., a set of secondary tubes 109 of the secondary heat exchanger section 110 may be coupled to the second vestibule panel 112 proximate outlets of the secondary tubes 109). The secondary tubes 109 may extend into the secondary heat exchanger section 110 and fluidly couple with the primary tubes 108 adjacent to a baffle. In some embodiments, a manifold, header, or other fluid distributor 114 may be coupled between the primary tubes 108 and the secondary tubes 109 to enable a fluid coupling between the primary tubes 108 and the secondary tubes 109.

[0054] The first vestibule panel 106 and the second vestibule panel 112 may be coupled to one or more components of an HVAC furnace, such as to an enclosure or a cabinet of the HVAC system or the furnace system 100, to facilitate securement of the furnace system 100 within the HVAC system and / or securement of various components of the furnace system 100. The first vestibule panel 106 and the second vestibule panel 112 may also be configured to couple to one another to block relative movement of different parts of the furnace system 100, such as relative movement of the primary heat exchanger section 104 and the secondary heat exchanger section 110. In some embodiments, the first vestibule panel 106 and the second vestibule panel 112 may be integrally formed as a single panel, such as from sheet metal.

[0055] As discussed herein, the furnace system 100 may also include a burner assembly 113 configured to ignite a mixture of fuel and oxidant to generate combustion products. For example, the burner assembly 113 may be fluidly coupled with inlets of the primary tubes 108 to direct combustion products through the inlets and into the primary tubes 108. The combustion products may flow through the primary tubes 108 and into the secondary tubes 109 of the secondary heat exchanger section 110. For example, the primary tubes 108 and the secondary tubes 109 may be coupled adjacent to a baffle, in some embodiments via the manifold, header, or other fluid distributor 114. As the furnace system 100 is operated, an air flow may be directed (e.g., by a fan or a blower) across the primary heat exchanger section 104 and the secondary heat exchanger section 110, such that the air flow is heated by the combustion products within the primary tubes 108 and the secondary tubes 109, and such that the combustion products are cooled by the air flow.

[0056] As previously described, operation of the furnace system 100 described above may cause condensate to form within the primary tubes 108 and / or the secondary tubes 109. For at least this reason, various aspects of the furnace system 100 may be arranged to reduce an impact of the liquid condensate on the furnace system 100. By way of example, components of the secondary heat exchanger section 110, such as the set of secondary tubes 109, the fluid distributor 114, and / or the second vestibule panel 112, may be made of stainless steel, chromium, and / or another suitable (e.g., corrosion resistant) material to block effects of the liquid condensate on the structural integrity and / or performance of the components.

[0057] In certain embodiments, the condensate may be less likely to contact components of, or otherwise impact, the primary heat exchanger section 104 than the secondary heat exchanger section 110 during operation of the furnace system 100 (e.g., due to formation of the liquid condensate within the secondary heat exchanger section 110 downstream of the primary heat exchanger section 104). For at least this reason, the components of the primary heat exchanger section 104, such as the set of primary tubes 108, the baffle or a portion thereof, and / or the first vestibule panel 106, may be made of a suitable material (e.g., carbon steel, rolled steel, galvanized steel) having less corrosion resistance than the material utilized to form components of the secondary heat exchanger section 110 and / or the second vestibule panel 112. Indeed, the components of the primary heat exchanger section 104 may be made of a different material, such as a less expensive material, than that of the components of the secondary heat exchanger section 110.

[0058] Further, in accordance with embodiments of the present disclosure and as illustrated in FIG. 5, the condensate pan 102 may be positioned adjacent to the outlets of the secondary tubes 109 (e.g., adjacent to the secondary heat exchanger section 110) and configured to receive liquid condensate formed in and / or flowing through the secondary heat exchanger section 110 (e.g., via the outlets of the secondary tubes 109). In some embodiments, the condensate pan 102 may be positioned external to the secondary heat exchanger section 110, such as between an inducer blower 116 and the second vestibule panel 112 of the furnace system 100. In accordance with present embodiments, and as shown in FIG. 5, the inducer blower 116 may be fastened to the condensate pan 102, such as via a mounting plate 118 (e.g. mounting surface, fixture plate, metal plate). However, in other embodiments, the condensate pan 102 may be configured to support the inducer blower 116 attached (e.g., directly attached) thereto without use of additional support structures (e.g. the mounting plate 118). In accordance with present embodiments, the condensate pan 102 may have an internal volume 200 configured to capture liquid condensate from the secondary tubes 109.

[0059] Embodiments of the condensate pan 102 disclosed herein may also be manufactured to include a relatively simple design that may be manufactured and / or installed within the furnace system 100 in a cost-effective manner. For example, as will be appreciated in view of the description below, the condensate pan 102 may be manufactured as a single piece structure that defines the internal volume 200 formed by a base wall 120, a first side wall 122A, a second side wall 122B, a third side wall 122C, and a forth side wall 122D (collectively referred to as side walls 122). The internal volume 200 extends along a first axis 300 (e.g., height axis) from the first side wall 122A to the second side wall 122B and extends along a second axis 302 (e.g., width axis) from the third side wall 122C to the fourth side wall 122D. In an embodiment, the internal volume 200 may extend side wall to side wall (e.g., first side wall 122A to second side wall 122B and third side wall 122C to fourth side wall 122D) substantially uninterrupted by walls, baffles, and / or other internal structures, reducing undesirable pressure drop and facilitating liquid condensate drainage.

[0060] A central opening 123 (e.g. internal volume opening, mouth) of the internal volume 200 may face the first vestibule panel 106 of the furnace system 100 in an installed configuration of the condensate pan 102 with the furnace system 100. Thus, the condensate pan 102 may cover or enclose outlets of the secondary tubes 109 of the secondary heat exchanger section 110. In this way, the condensate pan 102 (e.g., the internal volume 200) may receive and capture liquid condensate discharged from the secondary tubes 109 of the secondary heat exchanger section 110. Indeed, condensate pan 102 may form the internal volume 200 to have a relatively simple, open design without extra walls, panels, compartments and / or the like. In this way, the condensate pan 102 may be manufactured with reduced complexity while also enabling consistent pressures in the internal volume 200 during operation of the furnace system 100. In some embodiments, the internal volume 200 may include a larger cross-sectional area and / or volume (e.g., relative to traditional condensate pans) that may enhance collection of liquid condensate within the condensate pan 102.

[0061] The inducer blower 116 may be coupled to (e.g., directly to) the condensate pan 102 and / or to other equipment (e.g., the mounting plate 118) by one or more fasteners 124 that may extend into mounting recesses 154 (e.g., mounting apertures) formed in the base wall 120 of the condensate pan 102. The base wall 120 of the condensate pan 102 may also include an air flow aperture 150 (e.g., opening) to enable the inducer blower 116 to induce a flow of combustion products through the central opening 123 of the condensate pan 102 and the internal volume 200 of the condensate pan 102. In some embodiments, the condensate pan 102 may be coupled to the furnace system 70 (e.g., the second vestibule panel 112) via fasteners 126 extending through corresponding mounting apertures formed in outer flanges 128 (e.g., mounting flanges) of the condensate pan 102 and further into the second vestibule panel 112 to secure the condensate pan 102 to the second vestibule panel 112. The side wall 122 may extend from the base wall 120 to the outer flanges 128 along a third axis 304 (e.g., depth axis). Indeed, a length of the side walls 122 extending between the base wall 120 and the outer flanges 128 may be selected to reduce pressure drop between the inducer blower 116 and the first vestibule panel 106.

[0062] In other embodiments, the inducer blower 116, the condensate pan 102, and / or the second vestibule panel 112 may be coupled to one another in another suitable manner, such as via welding, adhesives, or any other combination thereof. In some embodiments, the condensate pan 102 may include a gasket (e.g., outer gasket) positioned against the base wall 120, which may be captured between the base wall 120 and the inducer blower 116 in an installed configuration of the inducer blower 116. In this way, a seal may be created between the inducer blower 116 and the condensate pan 102 to block inadvertent flow of liquid condensate and / or combustion products therebetween. In some embodiments, the condensate pan 102 may include a gasket (e.g., inner gasket) positioned against one or more of the outer flanges 128. The gasket may be captured between the condensate pan 102 and the second vestibule panel 112 in an installed configuration of the condensate pan 102. In this way, the gasket may provide a seal between the second vestibule panel 112 and the condensate pan 102 to block inadvertent flow of liquid condensate and / or combustion products therebetween.

[0063] As previously described, the condensate pan 102 may receive condensate formed during the operation of the furnace system 100. For instance, the condensate pan 102 may be fluidly coupled to the set of secondary tubes 109 of the secondary heat exchanger section 110 and may receive condensate formed within the secondary tubes 109 during operation of the furnace system 100, such as from the cooling of combustion products within the secondary tubes 109. Further, the condensate pan 102 may facilitate the flow of combustion products out of the primary heat exchanger section 104 and the secondary heat exchanger section 110. For example, during operation of the furnace system 100, the inducer blower 116 may draw combustion products into the condensate pan 102 through the central opening 123, through the internal volume 200, and through the air flow aperture 150 to discharge the combustion products from the furnace system 100, such as via an exhaust conduit 130. Liquid condensate that flows into the condensate pan 102 may also be discharged, such as via one or more drain ports formed in the condensate pan 102. For example, the furnace system 100 may include drain conduits 132 fluidly coupled to corresponding drain ports 180 to enable discharge of liquid condensate from the internal volume 200 of the condensate pan 102. Details of features of the condensate pan 102 in accordance with the present techniques are described in further detail below with reference to FIGS. 6-13.

[0064] FIG. 6 is a perspective view of an embodiment of the condensate pan 102, which may be incorporated with an embodiment of the furnace system 100 described above. As discussed above, the condensate pan 102 may include the base wall 120, and the base wall 120 may be configured to accommodate and support the inducer blower 116 mounted to (e.g., directly mounted to) the base wall 120. The inducer blower 116 may be mounted to the base wall 120, such that the inducer blower 116 (e.g., an inlet of the inducer blower 116) is aligned with the air flow aperture 150. Thus, the inducer blower 116 may operate to draw combustion products from the internal volume 200 of the condensate pan 102 and through the air flow aperture 150 to enable discharge of the combustion products from the furnace system 100. In some embodiments, a gasket 152 may be disposed about the air flow aperture 150 to create a sealing interface between the condensate pan 102 and the inducer blower 116.

[0065] The base wall 120 may also include the one or more mounting recesses 154 (e.g., mounting apertures) configured to receive respective fasteners (e.g., fasteners 124) to enable mounting of the inducer blower 116 directly to the base wall 120. In other embodiments, the inducer blower 116 may be mounted to the base wall 120 via another structural component, such as the mounting plate 118. The mounting recesses 154 may be formed at any location on the base wall 120. For example, one or more mounting recesses 154 may be disposed about (e.g., above, below, laterally outward) the air flow aperture 150 and at any distance from the air flow aperture 150. The mounting recesses 154 may be any size suitable configured to receive one of the fasteners 124 (e.g., screw, bolt) and / or an anchor. For example, the mounting recesses 154 may each have a diameter substantially the same as the diameter of one of the fasteners 124 and / or anchors in order to secure the fasteners 124 and / or anchors within the mounting recesses 154 and thereby secure the inducer blower 116 to the condensate pan 102. Accordingly, the combustion products and liquid condensate may be properly captured and discharged from the condensate pan 102 via the exhaust conduit 130 and / or the drain conduits 132. In some embodiments, the mounting recesses 154 may also receive and accommodate an anchor or screw boss that is configured to receive one of the fasteners 124. For example, anchors and / or screw bosses disposed within the mounting recesses 154 may define a recess or cavity configured to receive and engage with the fasteners 124 to securely retain the fasteners 124 therein and enable securement of the inducer blower 116 to the condensate pan 102. The anchors and / or screw bosses, as well as the fasteners 124, may be formed from a metallic material, while the condensate pan 102 may be formed from another material, such as a polymer (e.g., plastic). In this way, the fasteners 124 may physically engage with the anchors and / or screw bosses but may not physically engage with (e.g., deform) the base wall 120 or other part of the condensate pan 102. The anchors and / or screw bosses may be fixed inside the mounting recesses 154 in any suitable manner, such as mechanically or via an adhesive.

[0066] In some embodiments, the condensate pan 102 may include one or more extensions 156 extending outward (e.g., away) from one or more of the side walls 122 along the first axis 300 (e.g., height axis). Distal ends 158 of the extensions 156 may define one of the mounting recesses 154 (e.g., mounting apertures) offset from the base wall 120 and configured to receive one of the fasteners to enable mounting of the inducer blower 116 to the condensate pan 102. In other embodiments, other portions (e.g., intermediate portion, base portion) of the extensions 156 may define mounting recesses 154. The extensions 156 may extend from one of side walls 122 by any suitable dimension to enable mounting of the inducer blower 116 to the condensate pan 102 via corresponding mounting recesses 154 defined by the extensions 156. In some embodiments, the extensions 156 may be integrally formed with the condensate pan 102 to facilitate improved (e.g., more time-efficient, more cost-effective) manufacturing of the condensate pan 102 and / or to facilitate installment of the condensate pan 102 with the furnace system 100. The extensions 156 may extend from the side walls 122 at any suitable location to enable mounting of the inducer blower 116 to the condensate pan 102. For example, in some embodiments, one extension 156 may extend from the first side wall 122A, while another extension 156 may extend from the second side wall 122B. In an embodiment, the extensions 156 may overlap with a position of the air flow aperture 150 relative the first axis 300. Indeed, the location, length, and / or size of the extensions 156 may be selected based on mounting locations (e.g., apertures, features) of the inducer blower 116 and / or other equipment attached to the condensate pan 102.

[0067] Further, the condensate pan 102 may include the outer flanges 128 extending outward and substantially crosswise to the side walls 122 (e.g., along the axis 300). The outer flanges 128 may extend from the side walls 122 at any location along the side walls 122, such as a distal end 164 of each side wall 122 opposite an end 166 attached to the base wall 120. The outer flanges 128 may extend out by any desirable dimension to enable suitable attachment of the condensate pan 102 and the inducer blower 116 and / or equipment to the second vestibule panel 112. The outer flanges 128 may be any suitable thickness configured to support attachment of the condensate pan 102 to the second vestibule panel 112 of the furnace system 100. In some embodiments, the outer flanges 128 may include one or more mounting apertures 168 formed therethrough and configured to receive one of the fasteners 126 described above. In this way, the mounting apertures 168 may enable securement of the condensate pan 102 to the second vestibule panel 112. Further, the mounting apertures 168 may be any suitable size or shape and may be formed in the outer flanges 128 at any suitable locations. In some embodiments, a gasket may be disposed against one or more of the outer flanges 128 to create a sealing interface between the second vestibule panel 112 and the condensate pan 102. In this way, flow of liquid condensate and / or combustion products between the outer flanges 128 and the second vestibule panel 112 may be blocked.

[0068] The condensate pan 102 may also include one or more support ribs 170, extending from the side walls 122 to the outer flanges 128. The support ribs 170 may increase the rigidity of the condensate pan 102 and may further enable the condensate pan 102 to desirably support the inducer blower 116 mounted thereto. One or more of the support ribs 170 may be formed proximate to mounting apertures 168 of the outer flanges 128 in order to provide improved structural support in locations or regions that may experience additional mechanical stress. The support ribs 170 may be manufactured in any suitable shape, such as a triangular shape. In some embodiments, the support ribs 170 may extend from an exterior corner 172 of the condensate pan 102 that are defined by adjoining side walls 122. The support ribs 170 may be any thickness suitable to enable secure attachment and support of the inducer blower 116 to the condensate pan 102 and / or of the condensate pan 102 to the second vestibule panel 112. In some embodiments, one or more of the support ribs 170 may extend about one or more of the mounting apertures 168 located in a respective corner 174 of the outer flanges 128 to provide improved structural support.

[0069] In some embodiments, one or more of the outer flanges 128 may define a slot 176 (e.g., recess, cutout, indention) formed therein and located on an outer edge 178 of the outer flange 128. The slot 176 may receive a fastener or another support structure to further support the condensate pan 102 in attached configuration of the condensate pan 102 to the second vestibule panel 112. The slot 176 may be any suitable size or length and may be located at any position around the outer flange 128.

[0070] The condensate pan 102 further includes drain ports 180 (e.g., liquid condensate drain ports, drain apertures) configured to drain liquid condensate from the internal volume 200 and discharge the liquid condensate from the furnace system 100. To this end, the drain ports 180 may establish fluid communication between the internal volume 200 and an exterior of the condensate pan 102. In the illustrated embodiment, a first drain port 180A is formed through the base wall 120 of the condensate pan 102 at a first intersecting region 181A (e.g., intersection, junction, vertex) of the first side wall 122A and the third side wall 122C and a second drain port 180B is formed through the base wall 120 at a second intersecting region 181B of the second side wall 122B and the fourth side wall 122D. However, the drain ports 180 may be formed at other locations, such as at a third intersecting region between the second side wall 122B and the third side wall 122C or a fourth intersecting region between the first side wall 122A and the fourth side wall 122D. In this way, liquid condensate may flow or drain along an interior surface of the side walls 122 towards a respective drain port 180.

[0071] In some embodiments, the drain ports 180 may be formed in one or more side walls 122 of the condensate pan 102. The drain ports 180 may be any shape suitable to drain liquid condensate out from the internal volume 200 away from the furnace system 100. For example, the drain ports 180 may be circular, rectangular, polygonal or any other suitable shape. Further, the drain ports 180 may extend out of the base wall120 and away from the internal volume 200. In this way, the drain ports 180 may be configured to engage with a tube, hose, or other conduit to facilitate for drainage of the liquid condensate out of the condensate pan 102. In some embodiments, the drain ports 180 may have one or more ribs 182 (e.g., barbs) to facilitate the attachment of a tube conduit around the drain port 180.

[0072] In some embodiments, the condensate pan 102 may include multiple drain ports 180 to enable drainage of liquid condensate in multiple orientations of the furnace system 100. For example, the first drain port 180A may be positioned at a first corner 184 (e.g., proximate the first intersecting region 181A) of the base wall 120, and the second drain port 180B may be positioned at a second corner 186 (e.g., proximate the second intersecting region 181B) of the base wall 120, disposed diagonally opposite the first drain port 180A. In this way, at least one of the drain ports 180 will be configured to drain liquid condensate from the internal volume 200 in each orientation (e.g., vertical, horizontal, diagonal) of multiple orientations of the furnace system 100. For example, in the embodiment shown in FIG. 6, the first drain port 180A may drain liquid condensate from the internal volume 200, such as via force of gravity. In the illustrated embodiment, the second drain port 180B (e.g., the inactive or nonutilized drain port) may be plugged with any suitable plug to block liquid condensate, combustion gas, or other fluid within the internal volume 200 from inadvertently escaping from the condensate pan 102.

[0073] In another orientation of the furnace system 100 and the condensate pan 102, the condensate pan 102 may be rotated clockwise by approximately 90 degrees relative to the orientation shown in FIG. 6. In such an orientation, the drain port 180 located at the first corner 184 may be configured to drain a liquid condensate from the bottom of the internal volume 200 via force of gravity, while the drain port 180 formed in the second corner 186 of the base wall 120 may be plugged to block liquid condensate, combustion gas, or other fluid from inadvertently escaping from the condensate pan 102. In a further orientation, the condensate pan 102 may be rotated clockwise by approximately 180 degrees relative to the orientation shown in FIG. 6. In such an orientation, the drain port 180 located at the second corner 186 may be configured to drain liquid condensate from the bottom of the internal volume 200 via force of gravity, while the drain port 180 formed in the first corner 184 of the base wall 120 may be plugged to block liquid condensate, combustion gas, or other fluid from inadvertently escaping from the condensate pan 102. Similarly, in another orientation, the condensate pan 102 may be rotated counterclockwise by approximately 90 degrees relative to the orientation shown in FIG. 6, and the drain port 180 located at the second corner 186 may be configured to drain liquid condensate from the bottom of the internal volume 200 via force of gravity, while the drain port 180 formed in the first corner 184 of the base wall 120 may be plugged. In this way, an installer may install the furnace system 100 with the condensate pan 102 in multiple configurations while enabling desired drainage of liquid condensate with the condensate pan 102 in each orientation.

[0074] Further, in some embodiments, the condensate pan 102 may include one or more sensor ports 155 (e.g., pressure ports) defining sensor holes. The sensor ports 155 may be configured to receive and / or fluidly couple to sensor equipment (e.g., a sensor) configured to measuring a parameter associated with operation of the furnace system 100. For example, the sensor equipment coupled to the sensor ports 155 may enable detection of a property within the internal volume 200, such as pressure, temperature, humidity, air quality, flow, chemical composition, and so forth. Further, the sensor ports 155 may be positioned at any location desired, including the base wall 120 and / or the side walls 122. For example, a first sensor ports 155A may be positioned at corner of the base wall 120 defined by the second side wall 122B and the third side wall 122C, opposite the first drain port 180A and configured to detect a pressure within the internal volume 200 in a first orientation of the condensate pan 102 (e.g., an orientation associated with the first drain port 180A). A second sensor port 155B may be positioned at a corner of the base wall defined by the first side wall 122A and the fourth side wall 122D and configured to detect the pressure within the internal volume 200 in a second orientation of the condensate pan 102 (e.g., an orientation associated with the first drain port 180A. In some embodiments, the sensor ports 155 may include one or more ribs configured to facilitate the attachment of sensor equipment or other component to the sensor ports 155 and / or to create a seal between the sensor port 155 and sensor equipment.

[0075] In some embodiments, the furnace system 100 may be configured to alter operation (e.g., shut down) in response to a determination of condensate buildup in the internal volume 200 of the condensate pan 102. To this end, the furnace system 100 may also include a controller 157 (e.g., control system, thermostat, control panel, control circuitry, automation controller) that is communicatively coupled to one or more components of the furnace system 100 and is configured to monitor, adjust, and / or otherwise control operation of one or more components of the furnace system 100. For example, one or more control transfer devices, such as wires, cables, wireless communication devices, and the like, may communicatively couple the sensors and the one or more components of the furnace system 100 to the controller 157. That is the sensors and the one or more components of the furnace system 100 may each have one or more communication components that facilitate wired or wireless (e.g., via a network) communication with the controller 157. In some embodiments, the communication components may include a network interface that enables the components of the furnace system 100 to communicate via various protocols such as EtherNet / IP, ControlNet, DeviceNet, or any other communication network protocol. Alternatively, the communication components may enable the components of the furnace system 100 to communicate via mobile telecommunications technology, Bluetooth®, near-field communications technology, and the like. As such, the sensors and the one or more components of the furnace system 100 may wirelessly communicate data between each other.

[0076] As discussed above, in other embodiments, operational control of certain components of the furnace system 100 may be regulated by one or more relays or switches (e.g., a 24 volt alternating current [VAC] relay). For example, the sensor ports 155 may be configured to receive a condensate switch configured to detect condensate within the internal volume 200. The condensate switch may be electrically coupled to one or more components of the furnace system 100, such as the blower 66, a valve (e.g., electronic valve) configured to regulate fuel into the furnace system 100, and / or another suitable component of the furnace system 100. In response to condensate buildup within the internal volume exceeding a threshold value (e.g., threshold condensate buildup value), the condensate switch may shut off operation of the furnace system 100 (e.g., the one or more components), reducing degradation to the furnace system 100 due to undesirable buildup of condensate liquid. For example, in response to a pressure within the internal volume 200 exceeding a threshold pressure, the condensate switch may cut off or suspend power to one or more components of the furnace system 100.

[0077] In some embodiments, the controller 157 may be a component of or may include the control panel 82. In other embodiments, the controller 157 may be a standalone controller, a dedicated controller, or another suitable controller included in the furnace system 100. In any case, the controller 157 is configured to control components of the furnace system 100 in accordance with the techniques discussed herein. That is, the controller 157 is configured to output one or more control signals to control and / or adjust operation of components of the furnace system 100 described herein to disable operation of the furnace system 100 in response to condensate buildup. The controller 157 includes processing circuitry 159, such as a microprocessor, which may execute software for controlling the components of the furnace system 100. The processing circuitry 159 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and / or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processing circuitry 159 may include one or more reduced instruction set (RISC) processors.

[0078] The controller 157 may also include a memory device 161 (e.g., a memory) that may store information, such as instructions, control software, look up tables, configuration data, etc. The memory device 161 may include a volatile memory, such as random access memory (RAM), and / or a nonvolatile memory, such as read-only memory (ROM). The memory device 161 may store a variety of information and may be used for various purposes. For example, the memory device 161 may store processor-executable instructions including firmware or software for the processing circuitry 159 to execute, such as instructions for controlling components of the furnace system 100. In some embodiments, the memory device 161 is a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 159 to execute. The memory device 161 may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory device 161 may store data, instructions, and any other suitable data. It should be appreciated that the controller 157 may be configured to control operation of any and / or all of the components described herein to enable and facilitate the disclosed techniques.

[0079] As mentioned above, the controller 157 may alter operation of the one or more components of the furnace system 100 in response to condensate buildup and / or airflow blockage in the internal volume 200 of the condensate pan 102. For example, the controller 157 may be configured to disable operation of the furnace system 100 based on (e.g., in response to) one or more parameters within the internal volume 200. The one or more parameters of the internal volume 200 may be detected by one or more of the sensors described above. For example, in some embodiments, the controller 157 may be configured to disable operation (e.g., shut down) the furnace system 100 based on (e.g., in response to) a determination that a pressure within the internal volume 200 detected by one of the sensors is above a threshold pressure (e.g., threshold pressure value, stored on the memory device 161). The threshold pressure may be indicative of and / or may correspond to an undesirable amount of condensate buildup and / or airflow blockage.

[0080] The location of the sensor ports 155 may be selected based on the configuration of the furnace system 100, the type of sensor utilized with the sensor ports, locations of the drain ports 180, and / or other suitable factors. For example, in some embodiments, a sensor port 155 may receive a sensor configured to detect liquid buildup (e.g. pressure sensor, a liquid level sensor) within the condensate pan 102. In such embodiment, a sensor configured to detect liquid buildup may be located proximate to one of the drain ports 180, such as slightly above a height of a respective drain port 180. In this way, the sensor may detect liquid buildup beyond the height of the drain port 180 in certain configurations, which may indicate improper drainage of liquid condensate via the drain port 180. Additionally or alternatively, the furnace system 100 (e.g., the controller 157) may output a notification to a user so the user can determine a proper remedial action based on the indication provided by the sensor.

[0081] FIG. 7 is a rear perspective view of an embodiment of the condensate pan 102, including the base wall 120 and four side walls 122 defining an internal volume 200 of the condensate pan 102. The illustrated embodiment includes similar elements and element numbers as the embodiment shown in FIG. 6. In general, the configuration and / or amount of the heat exchange tubes (e.g., the secondary tubes 109) may be limited by the cross-sectional area of the internal volume 200. In some embodiments, the internal volume 200 of the condensate pan 102 may be manufactured in an efficient and cost-effective manner, such as via injection molding.

[0082] FIG. 8 is an expanded perspective view of an embodiment of the condensate pan 102. The illustrated embodiment includes similar elements and element numbers as the embodiment shown in FIG. 6. As discussed above, the condensate pan 102 may include the base wall 120 configured to enable mounting of the inducer blower 116 and / or other components of the furnace system 100 thereto. The base wall 120 further includes the air flow aperture 150 to enable the inducer blower 116 to draw combustion products therethrough. The air flow aperture 150 may be any shape (e.g. circular, rectangular, polygonal) desirable to enable flow of combustion products out of the furnace system 100 via the condensate pan 102. The air flow aperture 150 may have any suitable diameter or other dimension. Indeed, the shape and the size of the air flow aperture 150 may be selected based on a type of the furnace system 100, a type of the inducer blower 116, and / or design parameter of the furnace system 100.

[0083] Further, the base wall 120 may include a gasket rim 210 protruding from the base wall 120 in a direction away from the internal volume 200. The gasket rim 210 may be configured to receive, accommodate, support, and / or otherwise enable coupling of the gasket 152 to the base wall 120. The gasket 152 may be any size or shape desirable to create a seal between the inducer blower 116 and / or other equipment and the internal volume 200 without inhibiting flow of combustion products or other air flow through the air flow aperture 150. Further, the gasket 152 may be formed from any suitable material (e.g. rubber, metal, graphite, cork, felt, Teflon, synthetic fibers) to create a seal between the internal volume 200 and the inducer blower 116 and / or other equipment coupled to the base wall 120. In the illustrated embodiment, the condensate pan 102 also includes an anchor or screw boss 212 disposed within one of the mounting recesses 154. As discussed above, the screw boss 212 defines a recess or cavity configured to receive and engage with the fasteners 124 to securely retain the fasteners 124 therein and enable securement of the inducer blower 116 to the condensate pan 102. The screw boss 212 may be formed from a metallic material, while the condensate pan 102 may be formed from another material, such as a polymer (e.g., plastic). In this way, the fastener 124 may physically engage with the screw boss 212 but may not physically engage with (e.g., deform) the base wall 120 or other part of the condensate pan 102.

[0084] FIG. 9 is a perspective view of an embodiment of the furnace system 100, illustrating an embodiment of the condensate pan 102 and the mounting plate 118 (e.g., attachment plate) that may be incorporated in any of the systems of FIGS. 1-4, in accordance with an aspect of the present disclosure. In the illustrated embodiment, the mounting plate 118 is configured to facilitate attachment of the inducer blower 116 to the condensate pan 102 (e.g., the base wall 120). For example, the mounting plate 118 may include mounting plate holes configured to receive one or more fasteners 124 to enable mounting of the mounting plate 118 to the condensate pan 102. The fasteners 124 may be inserted through the mounting plate 118 and further into a mounting hole (e.g., mounting recess 154) in the base wall 120 of the condensate pan 102. In some embodiments, the mounting plate 118 may be a component of the inducer blower 116, such that securement of the mounting plate 118 to the condensate pan 102 facilitates mounting of the inducer blower 116 to the condensate pan 102. In other embodiments, the mounting plate 118 may be a separate component, and fasteners 124 may extend through the inducer blower 116 and the mounting plate 118 to secure the inducer blower 116 to the condensate pan 102. In this way, the mounting plate 118 may further support the attachment of the inducer blower 116 and / or other equipment to the condensate pan 102. The base wall 120 of the condensate pan 102 may also include mounting plate retainers 220 (e.g., guides, protrusions, tabs) extending from the base wall 120 and configured to facilitate alignment of the mounting plate 118 relative to the condensate pan 102 in a desired mounting position. For example, the plate retainers 220 may enable positioning of the mounting plate 118 relative to the condensate pan 102 such that mounting holes of the mounting plate 118 and mounting holes (e.g., mounting recess 154) of the base wall 120 are aligned with one another. The mounting plate retainers 220 may also be configured to provide vertical support for the mounting plate 118 in the attached position.

[0085] FIG. 10 is a cross-sectional side view of a portion of an embodiment of the furnace system 100, illustrating an embodiment of the condensate pan 102 and mounting plate 118. In some embodiments, the simplified design and shape of the condensate pan 102 may enable the condensate pan 102 to provide rigid support for the inducer blower 116 and / or other equipment secured to the condensate pan 102 and thereby to the furnace system 100. In this way, the condensate pan 102 may enable simplified manufacture, assembly, and installation of the furnace system 100. In some embodiments, the condensate pan 102 may be integrally formed as a single-piece construction (e.g., additively manufactured, injected molded, formed from sheet metal, or the like). In this way, the condensate pan 102 may be manufactured in expeditious and cost-effective manner. Further, the condensate pan 102 may be constructed from any suitable material, such as metal, a plastic, a composite, a polymer, or any other suitable material (e.g., corrosion resistant material) configured to enable capture and drainage liquid condensate. The single, integral piece design may also facilitate improved installation of the condensate pan 102 with the furnace system 100. Further, a single, integrally formed construction of the condensate pan 102 may a reduction in leakage of fluid (e.g., combustion products, liquid condensate) through joints that may otherwise be present in a multiple-piece construction of condensate pan assemblies.

[0086] FIG. 11 is a perspective view of an embodiment of the furnace system 100, illustrating the condensate pan 102 secured to the furnace system 100 without an embodiment of the mounting plate 118, in accordance with an aspect of the present disclosure. The illustrated embodiment includes similar elements and element numbers as described above. The condensate pan 102 may include inducer blower drain ports 240, separate from the drain ports 180, defining a hole, configured to receive liquid condensate from one or more locations in the inducer blower 116 and / or equipment. For example, liquid condensate building up in one or more areas of the inducer blower 116 may drain via a drain conduit 242 from the inducer blower 116, to the inducer blower drain port 240, and into the internal volume 200 of the condensate pan 102. Thereafter, the liquid condensate may be discharged from the condensate pan 102 via the drain port 180 in the manner described above. The inducer blower drain ports 240 may be any size or shape suitable to receive liquid from the inducer blower 116. The inducer blower drain ports 240 may be formed at any suitable location on the condensate pan 102, such as the base wall 120 and / or the side walls 122. The inducer blower drain ports 240 may be located proximate one or more of the drain ports 180 to facilitate desired liquid condensate drainage out of the furnace system 100. In some embodiments, the inducer blower drain ports 240 may include one or more ribs configured to facilitate sealed attachment of the drain conduit 242 to the inducer blower drain port 240. In an embodiment, the sensor port 155 may be fluidly coupled to a component of the inducer blower 116 via a pressure detection conduit 243. The pressure detection conduit 243 may facilitate detection of the pressure within the internal volume 200.

[0087] FIG. 12 is a perspective view of an embodiment of the furnace system 100, illustrating an embodiment of the condensate pan 102 secured to the furnace system 100 without the mounting plate 118. As illustrated, and in certain embodiments, the condensate pan 102 may be positioned and installed in between the vestibule (e.g., second vestibule panel 112) and the inducer blower 116 without additional structures (e.g. mounting plate 118). The condensate pan 102 may be integrally formed as a single-piece construction (e.g., additively manufactured, injected molded, formed from sheet metal, or the like) and may be designed to support the weight of the inducer blower 116 and / or other equipment in an attached configuration without additional structures (e.g. mounting plate 118). For example, through the insertion of fasteners 124 into the mounting recesses 154 formed in the base wall 120 of the condensate pan 102, or mounting holes of the extensions 156, the inducer blower 116 may be attached to the condensate pan 102. Further, fasteners 124 and / or anchors (e.g., screw bosses 212) configured to withstand vibrational forces may be incorporated to mitigate loosening of the fasteners 124 from the condensate pan 102. In this way, the furnace system 100 may be assembled more readily and reliably.

[0088] FIG. 13 is a side view of a portion of an embodiment of the furnace system 100, illustrating an embodiment of the condensate pan 102 installed without the mounting plate 118. As described above, the condensate pan 102 may be positioned in between the inducer blower 116 and the vestibule. The inducer blower 116 may be attached to the condensate pan 102 via fasteners 124 extending through mounting recesses 154 formed in the base wall 120 of the condensate pan 102 or mounting recesses 154 formed in the extensions 156 of the condensate pan 102. In some embodiments, as illustrated, some extensions 156 are configured to couple the condensate pan 102 to the vestibule via, for example, a fastener (e.g., fastener 124). In the illustrated embodiment, one mounting recess 154 of one of the extensions 156 of the condensate pan 102 is configured to receive a fastener to attach the condensate pan 102 to the vestibule (e.g., second vestibule panel 112). Another mounting recess 154 of another extension 156 is configured to receive a fastener to attach the inducer blower 116 to the condensate pan 102. Indeed, a greater distance between opposite distal ends 158 of the extensions 156 may increase structural support of the condensate pan 102 in the attached or installed configuration, thereby providing desired structural support for the inducer blower 116 mounted to the condensate pan 102.

[0089] While only certain features and embodiments of the disclosure have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, including temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

[0090] Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode of carrying out the disclosure, or those unrelated to enabling the claimed disclosure. It should be noted that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

[0091] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

1. A furnace for a heating, ventilation, and air conditioning (HVAC) system, wherein the furnace comprises:a condensate pan comprising a base wall and a plurality of side walls extending from the base wall, wherein the base wall and the plurality of side walls define an internal volume configured to receive liquid condensate from a tube of the furnace, the condensate pan comprises a first mounting aperture, a second mounting aperture, and a plurality of drain ports formed therein, each drain port of the plurality of drain ports extends through the base wall and is formed at an intersection of two side walls of the plurality of side walls, and the condensate pan is configured to mount to a panel of the furnace via a first fastener extending through the first mounting aperture; andan inducer blower configured to mount directly to the condensate pan via a second fastener extending through the second mounting aperture.

2. The furnace of claim 1, wherein the condensate pan is a single, integrally-formed piece.

3. The furnace of claim 1, wherein the plurality of drain ports comprises:a first drain port, wherein the first drain port is formed through the base wall at a first corner of the internal volume, and the first corner is defined by a first side wall and a second side wall of the plurality of side walls; anda second drain port, wherein the second drain port is formed through the base wall at a second corner of the internal volume, and the second corner is defined by a third side wall and a fourth side wall of the plurality of side walls.

4. The furnace of claim 3, wherein the first drain port and the second drain port are diagonally opposite one another relative to the internal volume.

5. The furnace of claim 3, wherein the condensate pan is configured to drain the liquid condensate from the internal volume via the first drain port in a first orientation of the condensate pan, and the condensate pan is configured to drain the liquid condensate from the internal volume via the second drain port in a second orientation of the condensate pan.

6. The furnace of claim 5, wherein the condensate pan comprises a first pressure port formed through the base wall proximate a third corner of the internal volume defined by the second side wall and the fourth side wall, and the furnace comprises a pressure detection conduit extending from the first pressure port to the inducer blower and configured to monitor a pressure within the internal volume in the first orientation of the condensate pan.

7. The furnace of claim 6, wherein the condensate pan comprises a second pressure port formed through the base wall proximate a fourth corner of the internal volume defined by the second side wall and the third side wall, and the pressure detection conduit extends from the second pressure port to the inducer blower to monitor the pressure within the internal volume in the second orientation of the condensate pan.

8. The furnace of claim 1, wherein the condensate pan comprises an outer flange extending from at least one side wall of the plurality of side walls, and the first mounting aperture extends through the outer flange.

9. The furnace of claim 1, comprising a metallic screw boss disposed within the second mounting aperture, wherein the second fastener is configured to engage with the metallic screw boss to mount the inducer blower directly to the condensate pan.

10. The furnace of claim 9, wherein the condensate pan comprises a third mounting aperture formed therein, the third mounting aperture is offset from the base wall, and the inducer blower configured to mount directly to the condensate pan via a third fastener extending through the third mounting aperture.

11. The furnace of claim 10, wherein the condensate pan comprises an extension extending from a side wall of the plurality of side walls, and the third mounting aperture is formed through a distal end of the extension.

12. A condensate pan for a furnace of a heating, ventilation, and / or air-conditioning, (HVAC) system, wherein the condensate pan comprises:a base wall;a plurality of side walls extending from the base wall and crosswise to the base wall;an internal volume defined by the base wall and the plurality of side walls, wherein the internal volume is configured to receive a heat transfer fluid and a liquid condensate from a heat exchanger of the furnace;a first drain port extending through the base wall and formed at a first corner of the internal volume defined by a first side wall of the plurality of side walls and a second side wall of the plurality of side walls, wherein the first drain port is configured to drain the liquid condensate from the internal volume to an exterior of the condensate pan in a first orientation of the condensate pan; anda second drain port extending through the base wall and formed at a second corner of the internal volume defined by a third side wall of the plurality of side walls and a fourth side wall of the plurality of side walls, wherein the second drain port is configured to drain the liquid condensate from the internal volume to the exterior of the condensate pan in a second orientation of the condensate pan.

13. The condensate pan of claim 12, wherein the first corner and the second corner are diagonally opposite one another relative to the internal volume.

14. The condensate pan of claim 12, comprising a plurality of outer flanges extending from the plurality side walls and crosswise to the plurality of side walls, wherein the plurality of outer flanges comprises a plurality of mounting apertures configured to receive a plurality of fasteners to mount the condensate pan to the heat exchanger.

15. The condensate pan of claim 12, comprising a plurality of mounting apertures integrally formed in the condensate pan, wherein the plurality of mounting apertures is configured to receive a plurality of fasteners to mount an inducer blower directly to the condensate pan.

16. The condensate pan of claim 15, wherein a first mounting apertures of the plurality of mounting apertures is formed through the base wall, and a second mounting aperture of the plurality of mounting apertures is offset from the base wall.

17. The condensate pan of claim 12, comprising an air flow aperture formed through the base wall and configured to direct the heat transfer fluid from the internal volume to an inducer blower of the furnace mounted directly to the condensate pan.

18. The condensate pan of claim 12, wherein the condensate pan is a single piece structure.

19. A furnace for a heating, ventilation, and air conditioning (HVAC) system, wherein the furnace comprises:a vestibule panel comprising a first side and a second side, opposite the first side;a burner assembly coupled to the vestibule panel and disposed on the first side of the vestibule panel, wherein the burner assembly is configured to generate combustion products;a first plurality of tubes coupled to vestibule panel and disposed on the second side of the vestibule panel, wherein the first plurality of tubes is configured to receive the combustion products from the burner assembly;a second plurality of tubes coupled to the vestibule panel and disposed on the second side of the vestibule panel, wherein the second plurality of tubes is configured to receive the combustion products from the first plurality of tubes;a condensate pan coupled to the vestibule panel and disposed on the first side of the vestibule panel, wherein the condensate pan defines an internal volume configured to receive the combustion products and a liquid condensate from the second plurality of tubes, the condensate pan comprises a first condensate drain port formed in a first corner of the internal volume and a second condensate drain port formed in a second corner of the internal volume, diagonally opposite the first corner, and the first condensate drain port and the second condensate drain port are each configured to direct the liquid condensate out of the internal volume in different orientations of the condensate pan; andan inducer blower mounted directly to the condensate pan and configured to draw the combustion products out of the internal volume.

20. The furnace of claim 19, wherein the condensate pan defines a first mounting aperture, a second mounting aperture, and an air flow aperture, the first mounting aperture and the air flow aperture are formed through a base wall of the condensate pan, the second mounting aperture is offset from the base wall, and the inducer blower is mounted directly to the condensate pan via a first fastener extending through the first mounting aperture and a second fastener extending through the second mounting aperture.

Images